I got a free band saw, but I think I have to modify it extensively to cut this wood-composite laminate I've created. This is a good time to reflect on the meaning of Building Things Backwards, and the process of acquiring "knowledge". Here I am, just trying to build a guitar. Yes, I got tricky with materials, but it doesn't affect the overall process. My process so far:
1. I got involved with composites
A. I built a heat box to cure composites
i) I had to struggle with foam and reflective bubble wrap
ii) I had to build a heater out of lights
iii) I had to test it for temperature range and stability
B. I layered the composite
i) I attempted to use weights to compress the stack slightly
a) I discovered the need for a clamping jig
ii) I discovered the practical need for a temperature controller
2. I had to cut this laminate
A. I tried a table saw with a plywood blade
B. I tried a router
C. I tried a hacksaw
D. I tried a band saw
i) I tried a cheap, stock wood-cutting blade
ii) I will try a bi-metal metal-cutting blade
iii) I will try to slow down the band saw speed so as not to overheat the plastic in the laminate
a) I will explore gearing down with pulleys
1. I will diagram the entire machine
2. I will discover what arrangement of pulleys will fit in the machine
3. I will learn the mathematics of pulleys
I) I will create more metal framing to support the new pulleys and jackshaft
i) I will explore making the pulley tension adjustable so the machine isn't intractable
ii) I will explore making the machine operate in both new and old configurations
b) I will explore using a DC treadmill motor
1. I will search the internet
2. I will search tag sales
I) I will learn to identify motor size by treadmill model
II) I will have to bring home a treadmill
III) I will have to dismantle a treadmill, preserving the parts I need
Maybe I'm not saying this well, or maybe I'm saying something too pointlessly obvious. My point, however, is that every time I hit a wall I have to dig backward in a tangentially-related discipline. Each time I do, I am going back in time to follow the tracks of other people who visualized these problems very clearly decades and centuries before I was born. "Band saw" to me means more than just a free saw that I have to recondition and tune up: it now means blueprints and engineering and pulley ratios and keyed shafts and pillow blocks and jackshafts. "Band saw", on a bad day when you have to cut something very strange, could be construed to mean, "All of engineering and physics."
I am constantly amazed by this process of blockage, regression, elaboration and breakthrough. I don't know if I'm getting closer to building a guitar, or farther. There is a part of me that is always discouraged at this process; that is also the part of me that would have settled for rediscovering fire after each lightning strike, rather than learning how create fire.
I am a monkey.
Yes, it does seem like it's turned into a massive undertaking. Have you researched what other guitar craftsmen use? I don't mean the big factories like Fender and Gibson. If you could track one of them down, maybe they'd be willing to reply to a friendly email asking for advice, or at least tool procurement. Whereas the heat box struck me as a "win" for homegrown ingenuity, messing around with pulley ratios on a band saw seems like rolling a boulder up a mountain. But maybe that's me. Studying pulleys in vector mechanics killed me in school.
ReplyDeleteheh....you said jackshaft
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